JP3964306B2

JP3964306B2 - Method for manufacturing stator laminated iron core of electric motor

Info

Publication number: JP3964306B2
Application number: JP2002316264A
Authority: JP
Inventors: 孝昭三井; 勝房藤田
Original assignee: Mitsui High Tech Inc
Current assignee: Mitsui High Tech Inc
Priority date: 2002-10-30
Filing date: 2002-10-30
Publication date: 2007-08-22
Anticipated expiration: 2022-10-30
Also published as: JP2004153928A

Description

【０００１】
【発明の属する技術分野】
本発明は、電動機の固定子、特に大型の固定子の製造に適した電動機の固定子積層鉄心の製造方法に関する。
【０００２】
【従来の技術】
従来、高出力、高トルクのモータ（電動機）に組み込まれている固定子積層鉄心（固定子積層コア）は、例えば外径が２０〜３０ｃｍ程度で大型のものがある。この固定子積層鉄心の内側には、軸心を向いて形成された複数の巻線用のスロットによって隣合う磁極部が複数形成されている。なお、固定子積層鉄心の磁極部の先端面により回転子収容孔が形成され、使用にあっては、この回転子収容孔に回転子を収容できる。
このような固定子積層鉄心を使用したモータは、作動時に固定子積層鉄心の温度上昇傾向が強くなる。このため、多数の固定子鉄心片の積層状態を維持させるため、及び別途の取付け装置に固定するための取付け孔を備えた突出部を、固定子積層鉄心の外周部に突出させた形態で複数設けることで、固定子積層鉄心の側背面に通風路を形成し、固定子積層鉄心の高温化を抑制、更には防止している（例えば、特許文献１参照。）。なお、取付け孔に固定ボルトを取付けることで、固定子積層鉄心を固定一体化できる。
しかし、固定子積層鉄心は多数の固定子鉄心片を積層して製造されるため、特に大型の固定子積層鉄心では、素材となる板材の板厚偏差の影響を受け易い。この板厚偏差により、固定子積層鉄心の磁極部の先端面に凹凸が発生したり、また先端面がジグザグ状になる恐れがあり、回転子収容孔の表面に凹凸が発生し、その形状が直円筒状にならず、固定子積層鉄心の品質が悪くなる。これを防ぐため、例えば積層時に固定子鉄心片を回し積み（転積）する方法が採用されている。
【０００３】
【特許文献１】
特開２００２−７８２５３号公報（第３頁左欄２０行目〜右欄３行目、図３）
【０００４】
【発明が解決しようとする課題】
しかしながら、取付け孔の位置決めが正確に行われていない固定子鉄心片を回し積みすると、回し積み時に上下方向の取付け孔の軸心がズレたり、スロットの位置が固定子積層鉄心内でズレて形状よく連通しなくなる可能性があり、積層した固定子積層鉄心を姿勢よく一様に固定できず、やはり固定子積層鉄心の品質が悪くなる恐れがある。
本発明はかかる事情に鑑みてなされたもので、複数形成された各スロットが位置ズレすることなく連通し、また回転子収容孔の表面が凹凸を呈することなく直円筒状で形状が優れ、特に大型であっても、姿勢よく一様に固定一体化した固定子積層鉄心を得ることが可能な電動機の固定子積層鉄心の製造方法を提供することを目的とする。
【０００５】
【課題を解決するための手段】
前記目的に沿う本発明に係る電動機の固定子積層鉄心の製造方法は、それぞれ軸心を向いて形成されたｍ個のスロットによって隣り合うｍ個の磁極部が軸心対称に形成された固定子鉄心片を、板材から打抜き、これらの固定子鉄心片を順次固定子鉄心片に設けられたかしめ部を介して多数かしめ積層する電動機の固定子積層鉄心の製造方法において、それぞれに円形取付け孔を有しかつ円形取付け孔の中心位置がスロット又は磁極部の半径方向中心線上に設けられたｎ個の突出部を、固定子鉄心片の磁気通路の更に外側に軸心対称に形成し、板材から固定子鉄心片をダイに抜き込み、ダイ内に積層された固定子鉄心片を順次所定角度回転しながら積層する組立工程を有する。なお、ｎはｍの約数である。このように、各円形取付け孔の中心位置を、スロット又は磁極部の半径方向中心線上に設けるので、スロット又は磁極部に対して、各円形取付け孔の位置決めを正確に行うことができる。これにより、ダイ内に抜き込まれた固定子鉄心片を順次所定角度回転しながら積層した場合においても、複数形成された各スロットが位置ズレすることなく連通し、かつ各固定子鉄心片の磁極部の先端面により形成される回転子収容孔の表面が凹凸を呈さず、直円筒状になる。
【０００６】
ここで、本発明に係る電動機の固定子積層鉄心の製造方法において、固定子鉄心片は、同一形状でかつ板材に対してそれぞれの位相が（１８０／ｎ）度異なる第１、第２の固定子鉄心片で構成され、組立工程は、円形取付け孔を形成して板材から第１の固定子鉄心片をダイに抜き込んだ後、第１の固定子鉄心片の円形取付け孔の軸心が、次に板材から打抜かれる第２の固定子鉄心片の円形取付け孔の軸心と同じ位置になるまでダイを所定角度回転させる第１工程と、円形取付け孔を形成して板材から打抜かれた第２の固定子鉄心片を、ダイに先に抜き込まれた第１の固定子鉄心片にかしめ積層した後、第２の固定子鉄心片の円形取付け孔の軸心が、次に板材から打抜かれる第１の固定子鉄心片の円形取付け孔の軸心と同じ位置になるまでダイを所定角度回転させる第２工程とを有し、第１、第２工程を繰返して所定高さの固定子積層鉄心を製造している。ここで、ダイを所定角度回転させることで、ダイに抜き込まれ積層された一部の固定子積層鉄心を所定角度回転させることができる。このように、位相が（１８０／ｎ）度異なる第１、第２の固定子鉄心片を板材から交互に打抜き、積層された固定子鉄心片を所定角度回転させた後、次に打抜かれる固定子鉄心片を積層するので、積層時における第１、第２の固定子鉄心片の回転角度を（３６０／ｎ）度より小さくできる。
【０００７】
本発明に係る電動機の固定子積層鉄心の製造方法において、固定子鉄心片は、同一形状でかつ板材に対してそれぞれの位相が（１８０／ｎ）度異なる第１、第２の固定子鉄心片で構成され、組立工程は、円形取付け孔を形成して板材から第１の固定子鉄心片をダイに抜き込み、第１の固定子鉄心片を複数かしめ積層した後、複数の第１の固定子鉄心片の円形取付け孔の軸心が、次に板材から打抜かれる第２の固定子鉄心片の円形取付け孔の軸心と同じ位置になるまでダイを所定角度回転させる第１工程と、円形取付け孔を形成して板材から打抜かれた第２の固定子鉄心片を複数、ダイに先に抜き込まれた第１の固定子鉄心片にかしめ積層した後、複数の第２の固定子鉄心片の円形取付け孔の軸心が、次に板材から打抜かれる第１の固定子鉄心片の円形取付け孔の軸心と同じ位置になるまでダイを所定角度回転させる第２工程とを有し、第１、第２工程を繰返して所定高さの固定子積層鉄心を製造することもできる。このように、位相が（１８０／ｎ）度異なる第１、第２の固定子鉄心片を板材から、複数枚ごと交互に打抜き、積層された固定子鉄心片を所定角度回転させた後、次に打抜かれる複数の固定子鉄心片を積層するので、積層時における第１、第２の固定子鉄心片の回転角度を（３６０／ｎ）度より小さくできる。
また、複数の第１の固定子鉄心片をかしめ積層した後、回転させ、更にこの第１の固定子鉄心片に複数の第２の固定子鉄心片をかしめ積層し、これを繰返すので、第１、第２の固定子鉄心片をダイに抜き込む毎に所定角度回転させる必要がなくなる。
【０００８】
【発明の実施の形態】
続いて、添付した図面を参照しつつ、本発明を具体化した実施の形態につき説明し、本発明の理解に供する。
ここに、図１（ａ）、（ｂ）はそれぞれ本発明の一実施の形態に係る電動機の固定子積層鉄心の製造方法における組立工程の第１工程の説明図、第２工程の説明図、図２は同方法を適用して製造した固定子積層鉄心の斜視図、図３は同方法における組立工程のスロット形成の説明図、図４は同方法に適用する固定子積層鉄心製造装置の説明図である。
【０００９】
まず、図２を参照しながら、本発明の一実施の形態に係る電動機の固定子積層鉄心の製造方法を適用して製造した固定子積層鉄心１０について説明する。
固定子積層鉄心１０は、材質が例えば珪素鋼板等からなって、板厚が例えば０．１５〜０．３ｍｍの板材の一例である条材Ａ（図１（ａ）、（ｂ）、図３参照）から金型によって打抜き形成される多数の第１、第２の固定子鉄心片（固定子鉄心片の一例）１１、１２を、順次所定角度（この実施の形態では６０度）回転しながら積層した製品であり、その形状は円筒状となっている。この第１、第２の固定子鉄心片１１、１２は、位相が（１８０／ｎ）度（この実施の形態では（１８０／３）＝６０度）異なった状態で条材Ａから打抜かれたものである。なおｎは、第１、第２の固定子鉄心片１１、１２にそれぞれ形成された突出部１８の個数を示す。
固定子積層鉄心１０の内側には、使用にあっては回転子（図示しない）を収容可能な回転子収容孔１３が設けられている。なお、図２に示された固定子積層鉄心１０は、組立てられた状態のものであるが、巻線は図示されていない。また、第１、第２の固定子鉄心片１１、１２は同一形状であるため、第１の固定子鉄心片１１についてのみ説明する。
【００１０】
第１の固定子鉄心片１１の内側には、それぞれ軸心Ｂを向いて形成されたｍ個（この実施の形態では３６個）のスロット１４によって隣り合うｍ個の磁極部１５が、第１の固定子鉄心片１１の軸心Ｂに点対称に形成されている。この磁極部１５は軸心Ｂに向かって徐々に拡幅しており、この磁極部１５の先端面１６により回転子収容孔１３が形成される。
また、各磁極部１５の基部（半径方向外側部）に連続する環状の磁気通路１７の更に外側には、平面視して矩形となったｎ個（この実施の形態では３個）の突出部１８が軸心Ｂに点対称に設けられている。そして、この突出部１８には、スロット１４の半径方向中心線Ｌ上に中心位置Ｐ（軸心）を配置した円形取付け孔１９が形成されている。ここで、円形取付け孔１９の中心位置Ｐと、第１の固定子鉄心片１１の軸心Ｂ、即ち回転子収容孔１３の軸心とを結ぶ線は、スロット１４の半径方向中心線Ｌと同一直線上にある。なお、ｎはｍの約数であるため、スロット１４及び磁極部１５は、突出部１８の個数に応じて均等に区分できる。
第１の固定子鉄心片１１の磁気通路１７には、下方（一方）に突出した複数（この実施の形態では１２個）のかしめ用突起（かしめ部の一例）２０が、磁極部１５の半径方向中心線上でかつ同一円周上に等間隔に設けられている。これにより、第１、第２の固定子鉄心片１１、１２を、順次第１、第２の固定子鉄心片１１、１２にそれぞれ設けられたかしめ用突起２０を介して多数かしめ積層することで、固定子積層鉄心１０を製造できる。
【００１１】
続いて、本発明の一実施の形態に係る電動機の固定子積層鉄心の製造方法について説明する。
図１（ａ）、（ｂ）、図３に示すように、本発明の一実施の形態に係る電動機の固定子積層鉄心の製造方法は、第１、第２の固定子鉄心片１１、１２を、条材Ａから前記した位相でそれぞれ打抜き、この第１、第２の固定子鉄心片１１、１２を順次第１、第２の固定子鉄心片１１、１２に設けられたかしめ用突起２０を介して多数かしめ積層する組立工程を有している。なお、組立工程は、ステーションＡ〜ステーションＦをそれぞれ備えた第１工程及び第２工程で構成される。
【００１２】
第１、第２の固定子鉄心片１１、１２のスロット１４形成は、第１、第２工程とも同じ方法で行われるため、第１工程のみ、図３を参照しながら説明する。
まず、図３に示すように、ステーションＡで、リール（図示しない）から巻戻された条材Ａの板幅方向の両側部に所定ピッチでガイドホール２１を形成する。そして、ステーションＢで、プレス加工により内形抜きを行い、続いてステーションＣで、プレス加工によりｍ個のスロット１４を形成すると共に、内側に回転子収容孔１３を形成する。更にステーションＤで、プレス加工により磁気通路１７に相当する部分にかしめ用突起２０を形成する。なお、積層１枚目となる固定子鉄心片には、かしめ用貫通孔が形成される。このかしめ用突起２０とかしめ用貫通孔の形成替えは、かしめ形成用パンチ（図示しない）のストリッパ下面への突出長さを、従来公知のカム・スライド機構により変えることで容易になされる。
これにより、第１、第２の固定子鉄心片１１、１２のスロット１４及びかしめ用突起２０が、条材Ａに形成される。
【００１３】
続いて、図１を参照して、第１、第２の固定子鉄心片１１、１２の円形取付け孔１９の形成を行うステーションＥ、及び第１、第２の固定子鉄心片１１、１２の打抜きと回し積み（転積）を行うステーションＦについて説明するが、まずステーションＥで使用する金型装置（図示しない）、及びステーションＦで使用する固定子積層鉄心製造装置（以下、単に鉄心製造装置とも言う）２２（図４参照）について説明する。
ステーションＥの金型装置には、円形取付け孔１９を設けた突出部１８を形成するための円形取付け孔形成パンチとダイ、及び開口部形成パンチとダイが、軸心対称に均等（６０度間隔）に６組配置されており、これら６組の円形取付け孔形成パンチ及び開口部形成パンチは、１組おきごとに間欠動作するようになっている。例えば、第１の固定子鉄心片１１を形成する際には、第１組、第３組、及び第５組の円形取付け孔形成パンチ及び開口部形成パンチが作動し、第２組、第４組、及び第６組の円形取付け孔形成パンチ及び開口部形成パンチは作動しない。また、第２の固定子鉄心片１２を形成する際には、第２組、第４組、及び第６組の円形取付け孔形成パンチ及び開口部形成パンチが作動し、第１組、第３組、及び第５組の円形取付け孔形成パンチ及び開口部形成パンチは作動しないようになっている。これら円形取付け孔形成パンチ及び開口部形成パンチの各組の作動切替えは、両パンチのストリッパ下面への突出長さを、従来公知のカム・スライド機構により変えることでなされる。
このステーションＥでは、前記したように、６組の円形取付け孔形成パンチ及び開口部形成パンチを、１組おきごとに間欠作動させることにより、第１、第２の固定子鉄心片１１、１２に突出部１８と円形取付け孔１９がそれぞれ形成される。
【００１４】
また、ステーションＦには、図４に示すように、例えば特開昭５９−１６５９４３号公報に開示された従来公知の鉄心製造装置２２が配置されている。この鉄心製造装置２２は上型部２３と下型部２４とを有し、上型部２３には、条材Ａから第１、第２の固定子鉄心片１１、１２を打抜くための打抜きパンチ２５が設けられ、下型部２４には、打抜かれた第１、第２の固定子積層鉄心片１１、１２を抜き込み積層可能なブランクダイ（ダイの一例）２６が設けられている。なお、ブランクダイ２６は、ブッシュ２７、カラー２８、ニードルベアリング２９等の介在によって回転可能となっており、ブランクダイ２６の外周に取付けられたスプロケット３０に掛けられ、モータ（図示しない）に連結されるリンクチェーン３１によって所定ピッチ（この実施の形態においては６０度）毎に回転し、ブランクダイ２６に抜き込まれる第１、第２の固定子鉄心片１１、１２が回し積みされるようになっている。
【００１５】
まず、図１（ａ）を参照しながら、第１の固定子鉄心片１１を製造する第１工程について説明する。
ステーションＥで、前記金型装置を使用し、第１組、第３組、及び第５組の円形取付け孔形成パンチ及び開口部形成パンチを作動させ、条材Ａに対して凹状の開口部３２を形成して、（３６０／３）度の角度で突出部１８を形成すると共に、円形取付け孔１９を形成する。
ステーションＦで、鉄心製造装置２２を使用して、第１の固定子鉄心片１１をブランクダイ２６中に抜き込んだ後、第１の固定子鉄心片１１の円形取付け孔１９の軸心が、次に条材Ａから打抜かれる第２の固定子鉄心片１２の円形取付け孔１９の軸心と同じ位置になるまでブランクダイ２６を所定角度、即ち（１８０／ｎ）度（この実施の形態では（１８０／３）＝６０度）回転させ、ブランクダイ２６内の第１の固定子鉄心片１１を前記所定角度回転させる。
【００１６】
次に、図１（ｂ）を参照しながら、第２の固定子鉄心片１２を製造する第２工程について説明する。
ステーションＥで、第１の固定子鉄心片１１の製造時に使用した第１組、第３組、及び第５組の円形取付け孔形成パンチ及び開口部形成パンチの作動を止め、第２組、第４組、及び第６組の円形取付け孔形成パンチ及び開口部形成パンチを作動させ、条材Ａに対して凹状の開口部３２を形成して、（３６０／３）度の角度で突出部１８を形成すると共に、円形取付け孔１９を形成する。
ステーションＦで、鉄心製造装置２２を使用して条材Ａから第２の固定子鉄心片１２を打抜き、ブランクダイ２６に先に抜き込まれた第１の固定子鉄心片１１の上に、かしめ用突起２０を介してかしめ積層する。そして、第２の固定子鉄心片１２の円形取付け孔１９の軸心が、次に条材Ａから打抜かれる第１の固定子鉄心片１１の円形取付け孔１９の軸心と同じ位置になるまでブランクダイ２６を所定角度、即ち（１８０／ｎ）度（この実施の形態では（１８０／３）＝６０度）回転させ、ブランクダイ２６内に積層された第１、第２の固定子鉄心片１１、１２を前記所定角度回転させる。
以上の第１、第２工程を繰返して、所定高さの前記固定子積層鉄心１０を製造する。
【００１７】
なお、第１の固定子鉄心片１１と第２の固定子鉄心片１２とを１枚ずつ交互にかしめ積層することなく、複数枚（例えば５枚）の第１の固定子鉄心片１１をかしめ積層した後、回転し、複数（例えば、第１の固定子鉄心片１１と同数である５枚）の第２の固定子鉄心片１２をかしめ積層して、第１の固定子鉄心片１１と第２の固定子鉄心片１２を複数枚交互にかしめ積層することも可能である。
この方法としては、第１工程で、第１の固定子鉄心片１１をブランクダイ２６に抜き込み、同様にして第１の固定子鉄心片１１を複数枚かしめ積層した後、複数の第１の固定子鉄心片１１の円形取付け孔１９の軸心が、次に条材Ａから打抜かれる第２の固定子鉄心片１２の円形取付け孔１９の軸心と同じ位置になるまでブランクダイ２６を所定角度回転させ、積層された複数の第１の固定子鉄心片１１を所定角度回転させる。次に、第２工程で、第２の固定子鉄心片１２を複数、好ましくは第１の固定子鉄心片１１と同数だけ、ブランクダイ２６に先に抜き込まれた第１の固定子鉄心片１１にかしめ積層し、積層された複数の第２の固定子鉄心片１２の円形取付け孔１９の軸心が、次に条材Ａから打抜かれる第１の固定子鉄心片１１の円形取付け孔１９の軸心と同じ位置になるまでブランクダイ２６を所定角度回転させ、ブランクダイ２６内に積層された複数の第１、第２の固定子鉄心片１１、１２を所定角度回転させる。
この第１、第２工程を繰返して、所定高さの固定子積層鉄心を製造する。
【００１８】
以上、本発明を、一実施の形態を参照して説明してきたが、本発明は何ら上記した実施の形態に記載の構成に限定されるものではなく、特許請求の範囲に記載されている事項の範囲内で考えられるその他の実施の形態や変形例も含むものである。例えば、前記したそれぞれの実施の形態や変形例の一部又は全部を組合せて本発明の電動機の固定子積層鉄心の製造方法を構成する場合も本発明の権利範囲に含まれる。
また、前記実施の形態においては、中心位置がスロットの半径方向中心線上に設けられた円形取付け孔を突出部に形成した場合について説明したが、中心位置が磁極部の半径方向中心線上に設けられた円形取付け孔を突出部に形成することも可能である。
【００１９】
そして、前記実施の形態においては、スロット及び磁極部の個数をそれぞれ３６個とした場合について説明したが、これに限定されるものでなく、例えば突出部の個数である３の倍数の４８個とすることも可能である。また、突出部の個数を３個とした場合について説明したが、これに限定されるものでなく、例えばスロットの個数である３６個の約数の４個とすることも可能である。
更に、前記実施の形態においては、固定子鉄心片として第１、第２の固定子鉄心片を複数枚積層して固定子積層鉄心を製造した場合について説明したが、固定子鉄心片として第１の固定子鉄心片のみ、又は第２の固定子鉄心片のみを複数枚使用し、これを所定角度（３６０／ｎ度）回転させて積層し、固定子積層鉄心を製造することも、また、例えば位相をずらした３以上の固定子鉄心片を使用して、固定子積層鉄心を製造することも可能である。
【００２０】
【発明の効果】
請求項１、２記載の電動機の固定子積層鉄心の製造方法においては、各円形取付け孔の中心位置を、スロット又は磁極部の半径方向中心線上に設けるので、スロット又は磁極部に対して、各円形取付け孔の位置決めを正確に行うことができる。これにより、ダイ内に抜き込まれた固定子鉄心片を順次所定角度回転しながら積層した場合においても、複数形成された各スロットが位置ズレすることなく連通し、かつ各固定子鉄心片の磁極部の先端面により形成される回転子収容孔の表面が凹凸を呈さず、直円筒状になる。従って、固定子積層鉄心を姿勢よく一様に固定一体化でき、回転子収容孔の表面形状が優れ、エアギャップを小さくできる等、形状及び品質の優れた固定子積層鉄心を製造することができる。
【００２１】
特に、請求項１記載の電動機の固定子積層鉄心の製造方法においては、位相が（１８０／ｎ）度異なる第１、第２の固定子鉄心片を板材から交互に打抜き、積層された固定子鉄心片を所定角度回転させた後、次に打抜かれる固定子鉄心片を積層するので、積層時における第１、第２の固定子鉄心片の回転角度を（３６０／ｎ）度より小さくできる。従って、各固定子鉄心片の板厚偏差を固定子積層鉄心の円周方向に更に均一に分散できるので、形状及び品質の優れた固定子積層鉄心を製造することができる。
また、請求項２記載の電動機の固定子積層鉄心の製造方法においては、複数の第１の固定子鉄心片をかしめ積層した後、回転させ、更にこの第１の固定子鉄心片に複数の第２の固定子鉄心片をかしめ積層し、これを繰返すので、積層時における第１、第２の固定子鉄心片の回転角度を（３６０／ｎ）度より小さくできる。従って、第１、第２の固定子鉄心片をダイに抜き込む毎に所定角度回転させる必要がなくなり、作業効率を向上させることができる。
【図面の簡単な説明】
【図１】（ａ）、（ｂ）はそれぞれ本発明の一実施の形態に係る電動機の固定子積層鉄心の製造方法における組立工程の第１工程の説明図、第２工程の説明図である。
【図２】同方法を適用して製造した固定子積層鉄心の斜視図である。
【図３】同方法における組立工程のスロット形成の説明図である。
【図４】同方法に適用する固定子積層鉄心製造装置の説明図である。
【符号の説明】
１０固定子積層鉄心、１１：第１の固定子鉄心片（固定子鉄心片）、１２：第２の固定子鉄心片（固定子鉄心片）、１３：回転子収容孔、１４：スロット、１５：磁極部、１６：先端面、１７：磁気通路、１８：突出部、１９：円形取付け孔、２０：かしめ用突起（かしめ部）、２１：ガイドホール、２２：固定子積層鉄心製造装置、２３：上型部、２４：下型部、２５：打抜きパンチ、２６：ブランクダイ（ダイ）、２７：ブッシュ、２８：カラー、２９：ニードルベアリング、３０：スプロケット、３１：リンクチェーン、３２：開口部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a stator laminated iron core of an electric motor suitable for manufacturing a stator of an electric motor, particularly a large stator.
[0002]
[Prior art]
Conventionally, a stator laminated core (stator laminated core) incorporated in a high-output, high-torque motor (electric motor) includes, for example, a large one having an outer diameter of about 20 to 30 cm. A plurality of adjacent magnetic pole portions are formed inside the stator laminated iron core by a plurality of winding slots formed facing the axis. In addition, a rotor accommodation hole is formed by the front end surface of the magnetic pole part of the stator laminated core, and in use, the rotor can be accommodated in this rotor accommodation hole.
A motor using such a stator laminated core has a strong tendency to increase the temperature of the stator laminated core during operation. For this reason, in order to maintain the stacked state of a large number of stator core pieces and to project a plurality of projecting portions provided with mounting holes for fixing to a separate mounting device in the outer peripheral portion of the stator stacked core By providing, the ventilation path is formed in the side back surface of a stator laminated core, and the high temperature of a stator laminated core is suppressed and further prevented (for example, refer patent document 1). In addition, a stator lamination | stacking iron core can be fixedly integrated by attaching a fixing bolt to an attachment hole.
However, since the stator laminated iron core is manufactured by laminating a large number of stator core pieces, particularly a large stator laminated iron core is easily affected by the thickness deviation of the plate material. Due to this thickness deviation, irregularities may occur on the tip surface of the magnetic pole part of the stator laminated core, or the tip surface may become zigzag. It does not become a straight cylinder, and the quality of the stator laminated iron core deteriorates. In order to prevent this, for example, a method of rotating and rolling (rolling) the stator core pieces during lamination is employed.
[0003]
[Patent Document 1]
JP 2002-78253 A (page 3, left column, 20th line to right column, 3rd line, FIG. 3)
[0004]
[Problems to be solved by the invention]
However, if the stator core pieces whose mounting holes are not accurately positioned are rotated and stacked, the axis of the mounting holes in the vertical direction will be misaligned and the slot positions will be misaligned in the stator stacking iron core. There is a possibility that it will not communicate well, and the laminated stator laminated core cannot be fixed uniformly in a good posture, and the quality of the stator laminated iron core may also deteriorate.
The present invention has been made in view of such circumstances, and a plurality of formed slots communicate with each other without being misaligned, and the surface of the rotor accommodating hole has a straight cylindrical shape with no irregularities, and is particularly excellent in shape. An object of the present invention is to provide a method for manufacturing a stator laminated core of an electric motor that can obtain a stator laminated core that is fixed and integrated uniformly with a good posture even if it is large.
[0005]
[Means for Solving the Problems]
In the method for manufacturing a stator laminated core of an electric motor according to the present invention that meets the above-described object, a stator in which m magnetic pole portions adjacent to each other are formed symmetrically with respect to an axis by m slots formed facing the axis. In the method of manufacturing a stator laminated core of an electric motor, in which a plurality of stator core pieces are punched from a plate material, and a plurality of these stator core pieces are sequentially caulked and laminated via a caulking portion provided on the stator core piece, each of which has a circular mounting hole. And n projecting portions whose center positions of the circular mounting holes are provided on the radial center line of the slot or the magnetic pole portion are formed axially symmetrically outside the magnetic path of the stator core piece, An assembly step of extracting the stator core pieces into a die and stacking the stator core pieces stacked in the die while sequentially rotating a predetermined angle; Note that n is a divisor of m. As described above, since the center position of each circular mounting hole is provided on the radial center line of the slot or the magnetic pole portion, each circular mounting hole can be accurately positioned with respect to the slot or the magnetic pole portion. Thereby, even when the stator core pieces extracted into the die are stacked while sequentially rotating at a predetermined angle, the plurality of formed slots communicate with each other without being displaced, and the magnetic poles of the stator core pieces The surface of the rotor accommodating hole formed by the tip surface of the part does not exhibit irregularities, and becomes a right cylindrical shape.
[0006]
Here, in the method for manufacturing a stator laminated core of an electric motor according to the present invention, the stator core pieces have the same shape, and the first and second fixings are different in phase from the plate material by (180 / n) degrees. In the assembly process, a circular mounting hole is formed, and after the first stator core piece is extracted from the plate into the die, the axis of the circular mounting hole of the first stator core piece is Next, a first step of rotating the die by a predetermined angle until the same position as the axis of the circular mounting hole of the second stator core piece to be punched from the plate material is formed, and the circular mounting hole is formed and punched from the plate material After the second stator core piece is caulked and laminated on the first stator core piece previously drawn into the die, the axis of the circular mounting hole of the second stator core piece is then the plate material. Die until it is in the same position as the axis of the circular mounting hole of the first stator core piece punched from And a second step of a predetermined angle, and first, by repeating the second step to produce a stator laminated core having a predetermined height. Here, by rotating the die by a predetermined angle, a part of the stator laminated iron cores extracted and stacked in the die can be rotated by a predetermined angle. As described above, the first and second stator core pieces whose phases are different by (180 / n) degrees are alternately punched from the plate material, and the stacked stator core pieces are rotated by a predetermined angle, and then punched. Since the stator core pieces are laminated, the rotation angle of the first and second stator core pieces at the time of lamination can be made smaller than (360 / n) degrees.
[0007]
In the method for manufacturing a stator laminated core of an electric motor according to the present invention, the stator core pieces have the same shape, and the first and second stator core pieces have different phases (180 / n) with respect to the plate material. In the assembly process, a circular mounting hole is formed, the first stator core pieces are extracted from the plate material into the die, and a plurality of first stator core pieces are caulked and stacked, and then a plurality of first fixings are made. A first step of rotating the die by a predetermined angle until the axis of the circular mounting hole of the core piece is in the same position as the axis of the circular mounting hole of the second stator core piece to be punched from the plate material; A plurality of second stator core pieces punched from the plate material by forming a circular mounting hole and caulking and stacking on the first stator core pieces previously drawn into the die, and then a plurality of second stator cores. The first stator core in which the axis of the circular mounting hole of the core piece is then punched from the plate material Possible for the die to the same position as the axis of the circular mounting hole and a second step of a predetermined angle, first, be repeated a second step for manufacturing the stator laminated core having a predetermined height . As described above, after the first and second stator core pieces whose phases are different by (180 / n) degrees are alternately punched out from the plate material every plurality of sheets, and the stacked stator core pieces are rotated by a predetermined angle, Since the plurality of stator core pieces to be punched are stacked, the rotation angle of the first and second stator core pieces at the time of stacking can be made smaller than (360 / n) degrees.
Further, after caulking and laminating a plurality of first stator core pieces, rotating, and further caulking and laminating a plurality of second stator core pieces on the first stator core pieces, and this is repeated. It is not necessary to rotate the first stator core piece by a predetermined angle each time the second stator core piece is extracted into the die.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
Here, FIGS. 1A and 1B are explanatory views of the first step and the second step of the assembly step in the method of manufacturing the stator laminated core of the electric motor according to the embodiment of the present invention, 2 is a perspective view of a stator laminated core manufactured by applying the method, FIG. 3 is an explanatory diagram of slot formation in the assembly process in the method, and FIG. 4 is an explanation of a stator laminated core manufacturing apparatus applied to the method. FIG.
[0009]
First, a stator laminated core 10 manufactured by applying a method for manufacturing a stator laminated core of an electric motor according to an embodiment of the present invention will be described with reference to FIG.
The stator laminated iron core 10 is made of, for example, a silicon steel plate or the like, and the strip material A (FIGS. 1A, 1B, 3) is an example of a plate material having a plate thickness of, for example, 0.15 to 0.3 mm. A number of first and second stator core pieces (an example of a stator core piece) 11, 12 formed by punching with a mold from a reference die, while sequentially rotating a predetermined angle (60 degrees in this embodiment). It is a laminated product, and its shape is cylindrical. The first and second stator core pieces 11 and 12 were punched from the strip A in a state where the phases were different by (180 / n) degrees (in this embodiment, (180/3) = 60 degrees). Is. In addition, n shows the number of the protrusion parts 18 formed in the 1st and 2nd stator core pieces 11 and 12, respectively.
A rotor housing hole 13 that can accommodate a rotor (not shown) in use is provided inside the stator laminated core 10. The stator laminated core 10 shown in FIG. 2 is in an assembled state, but the windings are not shown. Moreover, since the 1st, 2nd stator core pieces 11 and 12 are the same shapes, only the 1st stator core pieces 11 are demonstrated.
[0010]
Inside the first stator core piece 11, m magnetic pole portions 15 adjacent to each other by m (36 in this embodiment) slots 14 formed so as to face the axis B are first Are formed symmetrically about the axis B of the stator core piece 11. The magnetic pole portion 15 is gradually widened toward the axis B, and the rotor accommodating hole 13 is formed by the tip surface 16 of the magnetic pole portion 15.
Further, on the outer side of the annular magnetic passage 17 continuing to the base portion (radially outer portion) of each magnetic pole portion 15, there are n (three in this embodiment) projecting portions that are rectangular in plan view. 18 is provided symmetrically about the axis B. The projecting portion 18 is formed with a circular mounting hole 19 having a central position P (axial center) disposed on the radial center line L of the slot 14. Here, the line connecting the center position P of the circular mounting hole 19 and the axis B of the first stator core piece 11, that is, the axis of the rotor housing hole 13, is the radial center line L of the slot 14. It is on the same straight line. Since n is a divisor of m, the slot 14 and the magnetic pole part 15 can be equally divided according to the number of protrusions 18.
In the magnetic path 17 of the first stator core piece 11, a plurality of (12 in this embodiment) caulking projections (an example of caulking portions) 20 projecting downward (one side) are provided on the radius of the magnetic pole portion 15. They are provided at equal intervals on the direction center line and on the same circumference. As a result, the first and second stator core pieces 11 and 12 are sequentially caulked and stacked via the caulking protrusions 20 provided on the first and second stator core pieces 11 and 12 respectively. The stator laminated iron core 10 can be manufactured.
[0011]
Then, the manufacturing method of the stator laminated iron core of the electric motor which concerns on one embodiment of this invention is demonstrated.
As shown in FIGS. 1A, 1B, and 3, the method for manufacturing a stator laminated core of an electric motor according to an embodiment of the present invention includes first and second stator core pieces 11, 12. The first and second stator core pieces 11 and 12 are sequentially punched from the strip A in the above-described phase, and the caulking protrusions 20 are sequentially provided on the first and second stator core pieces 11 and 12. And an assembly process in which a large number of caulking layers are stacked. The assembly process includes a first process and a second process provided with stations A to F, respectively.
[0012]
Since the formation of the slots 14 of the first and second stator core pieces 11 and 12 is performed by the same method in both the first and second steps, only the first step will be described with reference to FIG.
First, as shown in FIG. 3, at the station A, guide holes 21 are formed at predetermined pitches on both sides in the plate width direction of the strip A that has been rewound from a reel (not shown). Then, at the station B, the inner shape is removed by pressing, and at the station C, the m slots 14 are formed by pressing and the rotor accommodating hole 13 is formed inside. Further, at station D, a caulking projection 20 is formed in a portion corresponding to the magnetic path 17 by pressing. A caulking through hole is formed in the stator core piece that is the first laminated layer. The rearrangement of the caulking projection 20 and the caulking through hole can be easily performed by changing the length of the caulking forming punch (not shown) protruding from the lower surface of the stripper by a conventionally known cam / sliding mechanism.
As a result, the slots 14 and the caulking projections 20 of the first and second stator core pieces 11 and 12 are formed on the strip A.
[0013]
Subsequently, referring to FIG. 1, the station E for forming the circular mounting holes 19 of the first and second stator core pieces 11, 12, and the first and second stator core pieces 11, 12. The station F that performs punching and rolling (rolling) will be described. First, a mold apparatus (not shown) used at the station E, and a stator laminated core manufacturing apparatus (hereinafter simply referred to as an iron core manufacturing apparatus) used at the station F. (Referred to as FIG. 4).
In the mold apparatus of station E, the circular mounting hole forming punch and die and the opening forming punch and die for forming the protrusion 18 provided with the circular mounting hole 19 are equally symmetrical (60 degree intervals). 6 sets are arranged, and these six sets of circular mounting hole forming punches and opening forming punches are intermittently operated every other set. For example, when the first stator core piece 11 is formed, the first set, the third set, and the fifth set of circular mounting hole forming punches and opening forming punches are operated, and the second set, the fourth set are operated. The set and the sixth set of circular mounting hole forming punch and opening forming punch do not operate. When the second stator core piece 12 is formed, the second set, the fourth set, and the sixth set of circular mounting hole forming punches and opening forming punches are operated, and the first set, the third set The set and the fifth set of circular mounting hole forming punches and opening forming punches are inoperative. The operation of each set of the circular mounting hole forming punch and the opening forming punch is switched by changing the length of protrusion of both punches on the lower surface of the stripper by a conventionally known cam / sliding mechanism.
In this station E, as described above, six pairs of circular mounting hole forming punches and opening forming punches are intermittently operated every other pair, so that the first and second stator core pieces 11 and 12 can be connected to each other. A protrusion 18 and a circular mounting hole 19 are formed respectively.
[0014]
Further, as shown in FIG. 4, a conventionally known iron core manufacturing apparatus 22 disclosed in, for example, Japanese Patent Application Laid-Open No. 59-165943 is disposed at the station F. This iron core manufacturing apparatus 22 has an upper mold part 23 and a lower mold part 24, and the upper mold part 23 is punched for punching the first and second stator core pieces 11, 12 from the strip A. A punch 25 is provided, and the lower die 24 is provided with a blank die (an example of a die) 26 capable of extracting and stacking the punched first and second stator laminated core pieces 11 and 12. The blank die 26 can be rotated by the intervention of a bush 27, a collar 28, a needle bearing 29, and the like. The blank die 26 is hung on a sprocket 30 attached to the outer periphery of the blank die 26 and connected to a motor (not shown). The first and second stator core pieces 11 and 12 which are rotated at a predetermined pitch (60 degrees in this embodiment) by the link chain 31 and are drawn into the blank die 26 are rotated and stacked. ing.
[0015]
First, the 1st process which manufactures the 1st stator core piece 11 is demonstrated, referring Fig.1 (a).
At station E, the first, third, and fifth sets of circular mounting hole forming punches and opening forming punches are actuated using the mold apparatus, and the opening 32 that is concave with respect to the strip A is formed. To form a protrusion 18 at an angle of (360/3) degrees and a circular mounting hole 19.
At the station F, after the first stator core piece 11 is drawn into the blank die 26 using the iron core manufacturing apparatus 22, the axis of the circular mounting hole 19 of the first stator core piece 11 is Next, the blank die 26 is moved to a predetermined angle, that is, (180 / n) degrees (this embodiment) until it reaches the same position as the axis of the circular mounting hole 19 of the second stator core piece 12 punched from the strip A. Then, (180/3) = 60 degrees), and the first stator core piece 11 in the blank die 26 is rotated by the predetermined angle.
[0016]
Next, the second step of manufacturing the second stator core piece 12 will be described with reference to FIG.
At station E, the first set, the third set, and the fifth set of circular mounting hole forming punch and opening forming punch used at the time of manufacturing the first stator core piece 11 are stopped, and the second set, The fourth and sixth sets of circular mounting hole forming punch and opening forming punch are actuated to form a concave opening 32 with respect to the strip A, and the protrusion 18 at an angle of (360/3) degrees. And a circular mounting hole 19 is formed.
At station F, the second stator core piece 12 is punched from the strip A using the iron core manufacturing apparatus 22 and caulked on the first stator core piece 11 previously drawn into the blank die 26. Caulking and lamination are performed via the projections 20 for use. Then, the axis of the circular mounting hole 19 of the second stator core piece 12 is located at the same position as the axis of the circular mounting hole 19 of the first stator core piece 11 to be punched from the strip A next. The blank die 26 is rotated by a predetermined angle, ie, (180 / n) degrees (in this embodiment, (180/3) = 60 degrees), and the first and second stator cores stacked in the blank die 26 are rotated. The pieces 11 and 12 are rotated by the predetermined angle.
The stator laminated core 10 having a predetermined height is manufactured by repeating the above first and second steps.
[0017]
It should be noted that a plurality of (for example, five) first stator core pieces 11 are caulked without alternately caulking and laminating the first stator core pieces 11 and the second stator core pieces 12 one by one. After the lamination, it is rotated, and a plurality of (for example, the same number of five first stator core pieces 11) second stator core pieces 12 are caulked and laminated to form the first stator core pieces 11. A plurality of second stator core pieces 12 may be alternately caulked and laminated.
In this method, in the first step, the first stator core pieces 11 are extracted into the blank die 26, and a plurality of first stator core pieces 11 are caulked and laminated in the same manner, and then a plurality of first stator core pieces 11 are stacked. The blank die 26 is moved until the axial center of the circular mounting hole 19 of the stator core piece 11 is located at the same position as the axial center of the circular mounting hole 19 of the second stator core piece 12 to be punched from the strip A. The plurality of stacked first stator core pieces 11 are rotated by a predetermined angle to rotate by a predetermined angle. Next, in the second step, a plurality of the second stator core pieces 12, preferably the same number as the first stator core pieces 11, are first drawn into the blank die 26 first. 11 and the shaft mounting holes 19 of the plurality of second stator core pieces 12 stacked are caulked and then the circular mounting holes of the first stator core pieces 11 are punched from the strip A. The blank die 26 is rotated by a predetermined angle until it reaches the same position as the 19 axis, and the plurality of first and second stator core pieces 11 and 12 stacked in the blank die 26 are rotated by a predetermined angle.
The first and second steps are repeated to produce a stator laminated iron core having a predetermined height.
[0018]
As described above, the present invention has been described with reference to one embodiment. However, the present invention is not limited to the configuration described in the above embodiment, and is described in the claims. Other embodiments and modifications conceivable within the scope of the above are also included. For example, a case where a method for manufacturing a stator laminated core of an electric motor of the present invention is configured by combining some or all of the above-described embodiments and modifications is also included in the scope of the present invention.
In the above-described embodiment, the case where the circular mounting hole whose center position is provided on the radial center line of the slot is formed in the projecting portion has been described. However, the center position is provided on the radial center line of the magnetic pole part. It is also possible to form a circular mounting hole in the protrusion.
[0019]
In the embodiment described above, the case where the number of slots and the number of magnetic pole portions is 36 has been described. However, the present invention is not limited to this. For example, the number of protrusions is a multiple of 3 which is 48. It is also possible to do. In addition, although the case where the number of protrusions is three has been described, the present invention is not limited to this, and for example, it is possible to use four divisors of 36, which is the number of slots.
Further, in the above-described embodiment, the case where the stator laminated core is manufactured by laminating a plurality of first and second stator core pieces as the stator core pieces has been described. It is also possible to produce a stator laminated core by using only a plurality of stator core pieces or a plurality of second stator core pieces and rotating them by a predetermined angle (360 / n degrees) to laminate them. For example, it is also possible to manufacture a stator laminated core by using three or more stator core pieces whose phases are shifted.
[0020]
【The invention's effect】
In the method of manufacturing a stator laminated core for an electric motor according to claim 1 or 2, the center position of each circular mounting hole is provided on the radial center line of the slot or magnetic pole portion. The circular mounting hole can be accurately positioned. Thereby, even when the stator core pieces extracted into the die are stacked while sequentially rotating at a predetermined angle, the plurality of formed slots communicate with each other without being displaced, and the magnetic poles of the stator core pieces The surface of the rotor accommodating hole formed by the tip surface of the part does not exhibit irregularities, and becomes a right cylindrical shape. Therefore, it is possible to manufacture a stator laminated core having excellent shape and quality such that the stator laminated iron core can be fixed and integrated uniformly with a good attitude, the surface shape of the rotor housing hole is excellent, and the air gap can be reduced. .
[0021]
In particular, in the manufacturing method of the stator laminated core of an electric motor according to claim 1, punching alternately first the different phases (180 / n) degrees, the second stator core sheets from the sheet material, are laminated stator Since the stator core pieces to be punched next are stacked after rotating the core pieces by a predetermined angle, the rotation angle of the first and second stator core pieces at the time of stacking can be made smaller than (360 / n) degrees. . Therefore, since the thickness deviation of each stator core piece can be more uniformly distributed in the circumferential direction of the stator laminated core, a stator laminated core having excellent shape and quality can be manufactured.
In the method of manufacturing a stator laminated core for an electric motor according to claim 2 , a plurality of first stator core pieces are caulked and laminated, and then rotated, and further, a plurality of first stator core pieces are attached to the first stator core piece. Since the two stator core pieces are caulked and laminated, and this is repeated, the rotation angle of the first and second stator core pieces during lamination can be made smaller than (360 / n) degrees. Accordingly, it is not necessary to rotate the first and second stator core pieces by a predetermined angle every time the first and second stator core pieces are extracted into the die, and the working efficiency can be improved.
[Brief description of the drawings]
FIGS. 1A and 1B are respectively an explanatory diagram of a first step and an explanatory diagram of a second step in a method of manufacturing a stator laminated core for an electric motor according to an embodiment of the present invention. .
FIG. 2 is a perspective view of a stator laminated core manufactured by applying the method.
FIG. 3 is an explanatory diagram of slot formation in an assembly process in the same method.
FIG. 4 is an explanatory view of a stator laminated core manufacturing apparatus applied to the method.
[Explanation of symbols]
10 stator laminated core, 11: first stator core piece (stator core piece), 12: second stator core piece (stator core piece), 13: rotor receiving hole, 14: slot, 15 : Magnetic pole part, 16: tip surface, 17: magnetic path, 18: protrusion, 19: circular mounting hole, 20: caulking protrusion (caulking part), 21: guide hole, 22: stator laminated core manufacturing apparatus, 23 : Upper mold part, 24: Lower mold part, 25: Punch punch, 26: Blank die (die), 27: Bush, 28: Collar, 29: Needle bearing, 30: Sprocket, 31: Link chain, 32: Opening

Claims

A stator core piece in which m magnetic pole portions adjacent to each other are formed symmetrically about the axis by m slots formed facing the axis is punched from the plate material, and these stator core pieces are sequentially moved to the stator. In the method of manufacturing a stator laminated core of an electric motor that is caulked and laminated in large numbers via caulking portions provided on an iron core piece,
N protrusions each having a circular mounting hole and having a central position on the radial center line of the slot or the magnetic pole portion are further outside the magnetic path of the stator core piece. To be symmetrical about the axis,
The narrowing disconnect the stator core pieces from sheet material in the die, the stator core pieces are laminated sequentially have a predetermined angle while the assembly process of laminating within the die,
The stator core pieces are composed of first and second stator core pieces having the same shape and different phases (180 / n) degrees with respect to the plate material,
The assembly process includes
After forming the circular mounting hole and extracting the first stator core piece from the plate material into the die, the shaft center of the circular mounting hole of the first stator core piece is next from the plate material. A first step of rotating the die by a predetermined angle until the same position as the axial center of the circular mounting hole of the second stator core piece to be punched;
The second stator core piece punched from the plate member by forming the circular mounting hole is caulked and stacked on the first stator core piece previously drawn into the die, and then the second The die is rotated by a predetermined angle until the axial center of the circular mounting hole of the stator core piece is the same position as the axial center of the circular mounting hole of the first stator core piece to be punched from the plate. A second step,
A method for producing a stator laminated core of an electric motor , wherein the stator laminated iron core having a predetermined height is produced by repeating the first and second steps .
Note that n is a divisor of m.

A stator core piece in which m magnetic pole portions adjacent to each other are formed symmetrically about the axis by m slots formed facing the axis is punched from the plate material, and these stator core pieces are sequentially moved to the stator. In the method of manufacturing a stator laminated core of an electric motor that is caulked and laminated in large numbers via caulking portions provided on an iron core piece,
N protrusions each having a circular mounting hole and having a central position on the radial center line of the slot or the magnetic pole portion are further outside the magnetic path of the stator core piece. To be symmetrical about the axis,
The narrowing disconnect the stator core pieces from sheet material in the die, the stator core pieces are laminated sequentially have a predetermined angle while the assembly process of laminating within the die,
The stator core pieces are composed of first and second stator core pieces having the same shape and different phases (180 / n) degrees with respect to the plate material,
The assembly process includes
After forming the circular mounting hole and extracting the first stator core pieces from the plate into a die and caulking and laminating a plurality of the first stator core pieces, a plurality of the first stator core pieces are obtained. A first step of rotating the die by a predetermined angle until the axis of the circular mounting hole is positioned at the same position as the axis of the circular mounting hole of the second stator core piece that is then punched from the plate;
A plurality of the second stator core pieces punched from the plate material by forming the circular mounting hole, and after caulking and laminating the first stator core pieces previously drawn into the die, a plurality of The die is predetermined until the axis of the circular mounting hole of the second stator core piece is located at the same position as the axis of the circular mounting hole of the first stator core piece that is then punched from the plate material. A second step of rotating the angle,
A method for producing a stator laminated core of an electric motor , wherein the stator laminated iron core having a predetermined height is produced by repeating the first and second steps .
Note that n is a divisor of m.